Automated Cap Assembly with Robotized Handling and Heat Sealing
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Solution Overview
Problem
Existing methods for assembling caps for power storage units, such as batteries, suffer from low repeatability, safety concerns for operators, and reduced productivity due to manual handling and testing processes, leading to inconsistent connections and potential inaccuracies in the heat sealing process.
Innovation Solution
An automated apparatus with feeding, heating, pressing, cooling, and testing stations, along with robotized handling means, is used to precisely assemble and test caps, ensuring high repeatability, safety, and productivity by automating the handling of ceramic and plastic components and incorporating non-destructive testing for all produced units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual handling and testing processes are used, then operator flexibility is maintained, but productivity is reduced and repeatability is poor
Solution Approach 1:
The patent replaces manual mechanical operations with an automated robotic system that includes a robotized arm for handling components, an automated pressing station for heat sealing, and automated testing equipment. This substitution dramatically increases productivity while maintaining precise control over the assembly process parameters.
Solution Approach 2:
The automated system performs all assembly and testing operations autonomously without requiring continuous human intervention. The robotized handling means automatically positions components, the pressing station autonomously applies heat and pressure, and the testing equipment self-evaluates each cap, enabling continuous operation at high speed.
2Manufacturing precision
If manual positioning of heated filters is performed, then operator control is direct, but precision and repeatability of heat sealing are reduced
Solution Approach 1:
The patent replaces manual positioning with automated robotic positioning systems that use programmable coordinates and sensors to place the ceramic filter and plastic base with high precision. The robotized arm can repeatedly position components at the same location with micrometer-level accuracy, ensuring consistent heat sealing quality.
Solution Approach 2:
The system incorporates sensors and control systems that monitor the positioning of components during assembly. The feedback mechanism allows the automated system to detect and correct positioning deviations, ensuring that the heated filter is always positioned correctly relative to the plastic base for optimal heat sealing.
3Reliability
If operator performs multiple operations in quick succession, then task completion is achieved, but accuracy of results may be invalidated and safety is compromised
Solution Approach 1:
The patent combines multiple separate operations (component handling, heating, positioning, heat sealing, and testing) into a single integrated automated system. The robotized handling means, heating station, pressing station, and testing equipment work as a coordinated unit, eliminating the need for operators to perform multiple discrete operations manually and reducing human error.
Solution Approach 2:
The automated robotic system acts as an intermediary between the various processing stations, coordinating the flow of components and synchronizing operations. The control system mediates between the heating station, pressing station, and testing equipment, ensuring that each operation is performed at the correct time with the correct parameters, thereby maintaining high reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The apparatus achieves precise and repeatable cap assembly with enhanced operator safety, significantly increasing productivity while ensuring all units undergo thorough testing, resulting in improved quality and efficiency of the cap assembly process.
Implementation Method 1
The plastic and ceramic components are assembled together using a heat sealing process in which the ceramic filter is heated (170°-190° C) followed by pressing of the filter on the plastic base which melts locally, thus forming the join between the parts of the cap.
Implementation Method 2
The plastic and ceramic components are assembled together using a heat sealing process in which the ceramic filter is heated (170°-190° C) followed by pressing of the filter on the plastic base which melts locally, thus forming the join between the parts of the cap.
Data Source
Figure 1
Figure 2
Figure 3~4a
AI summary
An apparatus for assembling caps having at least a supporting body (50) of plastic material and a filter element (51) of ceramic material, comprises a feeding station (2) for a succession of supporting bodies (50), a feeding station (3) for a succession of filter elements (51) which is equipped with heating means (4) configured to raise the temperature of the filter elements (51), a pressing station (5) set up to receive a heated filter element (51) and at least one corresponding supporting body (50) and to couple them to each other by heat sealing to form a cap (100), a cooling station (6) and a testing station (7) set up to receive the at least one cap (100) from the cooling station (6) and configured to measure values of at least one parameter representing a correct operation of the cap. The apparatus also comprises robotized handling means (10) connected to the base (15) and operating on the supporting bodies (50), the filter elements (51) and the caps (100) in such a way as to pick them up and transport them automatically between the stations (2, 3, 5, 6, 7) to the next station.